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Service Manual
AIR PROCESSING UNIT
ZB44..
Y025030 - (EN - Rev. 003)
Pressure regulator
G1
Pressurised air
18 Bar
Check valve
Nozzle
T1
T2
Ø nozzle defined in procedure
Used part of test bench
Unused part of test bench
NOVEMBER 2014
T5
T6
20 l
G2
T7
T8
20 l
G3
T9
T10
1
21
0.25 l
T11
G4
T12
22
0.25 l
ZB44..
T13
T14
G5
type APU
23
0.25 l
T15
G6
T16
24
29
0.25 l
3
T3
T4
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Table of Contents
Related Manuals for Knorr-Bremse ZB44 Series
Summary of Contents for Knorr-Bremse ZB44 Series
- Page 1 Y025030 - (EN - Rev. 003) NOVEMBER 2014 Service Manual 20 l 20 l Pressure regulator Pressurised air 18 Bar Check valve Nozzle 0.25 l 0.25 l ZB44.. type APU 0.25 l Ø nozzle defined in procedure Used part of test bench 0.25 l Unused part of test bench AIR PROCESSING UNIT...
- Page 2 The information contained herein is intended for the exclusive use of trained persons within the commercial vehicle industry, and must not be passed on to any third party. All recommendations regarding products and their servicing or usage are with reference to Knorr-Bremse products and should not be considered applicable to products from other manufacturers.
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Page 3: Table Of Contents
Contents Contents Safety and Environment Guidelines Introduction Service Intervals . Basic Principles Components Serviceable Components of the Air Processing Unit . Service Instructions Removal and Replacement of the Desiccant Cartridge (A) . . 10 Removal and Replacement of the Heater Assembly (B) . . - Page 4 Ensure that adequate support or assistance is provided for the removal/installation of heavy items. Use only genuine replacement parts, components and kits as supplied by Knorr-Bremse or the vehicle manufacturer. The serviced or replaced product must be checked for correct function and effectiveness.
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Page 5: Introduction
(filter elements and Knorr-Bremse service kit or replaced with a new part, or in springs), fasteners and the correct grease. The range of the case of ABS subjected to a system functionality check. -
Page 6: Basic Principles
Introduction Basic principles The ZB44.. range of air processing units combines the functions of a conventional air dryer with those of a pressure regulator and multi-circuit protection valve in one monoblock housing. 1 2 1 Features • Classic air drying functionality •... - Page 7 Introduction Unloader function During the Purge phase, the loss of pressure in the inlet cavity will close the delivery check valve. Some dry air The pressure after the delivery check valve also flows to from the brake service reservoirs is permitted to return the unloader valve.
- Page 8 Introduction Static closing pressure Bypass The static closing pressure is the pressure at which the The bypass feature is an air passage in each circuit 21 and valve element will close in the event of slow air usage 22 which connects the supply to the respective delivery (e.g.
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Page 9: Components
Components Serviceable Components of the Air Processing Unit Exploded View Part Identification and Service Kits For Service Kit Part Number see www.knorr-bremseCVS.com Item Description Comments / Variants For standard applications Desiccant cartridge For low temperature applications (-45 ºC) Heater 12 V 27x1 Heater assembly Heater 24 V 27x1 Heater 24 V Bayonet - ISO15170... -
Page 10: Service Instructions
Service Instructions 3 1 Removal and Replacement of the Desiccant Cartridge (A) Part Identification Item Description Desiccant cartridge O-ring Note that component numbering may not correspond to that shown on separate Service Kit leaflets. For Service Kit Part Number see www.knorr-bremseCVS.com Service Steps Step Service task... -
Page 11: Removal And Replacement Of The Heater Assembly (B)
Service Instructions 3 2 Removal and Replacement of the Heater Assembly (B) Part Identification Item Description Heater assembly Screw Note that component numbering may not correspond to that shown on separate Service Kit leaflets. For Service Kit Part Number see www.knorr-bremseCVS.com M27x1 (12V &... -
Page 12: Removal And Replacement Of The Silencer Assembly (C)
Service Instructions 3 3 Removal and Replacement of the Silencer (C) Part Identification Item Description Silencer assembly For Service Kit Part Number see www.knorr-bremseCVS.com Service Steps Step Service task Removal of the silencer assembly Remove silencer assembly (1) Replacement of the silencer assembly Locate new silencer assembly (1) over its spigot on the base of the air processing unit. -
Page 13: Removal Of The Air Processing Unit From The Vehicle
Service Instructions 3 4 Removal of the Air Processing Unit from the Vehicle Fig. 1 Fig. 2 Service Steps Step Service task Before starting work on the vehicle please refer to the safety checks on page 4. Vent the system air pressure completely. Disconnect air lines after noting which port they are connected to for correct reinstallation. -
Page 14: Removal And Replacement Or Service Of The Oil Separator Unit (D)
Service Instructions 3 5 Removal and Replacement or Service of the Oil Separator Unit (D) Part Identification and Service Kits Item Description Oil separator unit • O-ring Ø 92 x 2.5 mm • O-ring Ø 42 x 2.5 mm Screw M 4 x 40 mm •... - Page 15 Service Instructions Service Steps Removing the oil separator Step Service task Clean the outside of the air processing unit and its surroundings to prevent entry of dirt. Secure the ZB44.. either to a simple fixture or using the mounting bolts/studs to make it stable. Unscrew desiccant cartridge (6) counter-clockwise, using suitable strap wrench.
- Page 16 Service Instructions Recommended pulling tool for Oil Separator Unit disassembly Holder with threaded bolt Adjustable pulling arms Thrust plate for threaded bolt Correct fitting of pulling tool Components of pulling tool Ø35 90º max 3º 15º 90º Ø3 Ø20 Dimensions of thrust plate Dimensions of pulling tool legs...
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Page 17: Disassembling And Assembling The Purge Valve (E)
Service Instructions 3 6 Disassembling and Assembling the Purge Valve (E) Service kit parts list Item Description Air Processing Unit (APU) housing • Retaining ring Ø 27,2 x 1,2 1 • O-ring Ø 24 x 1,5 1 • Exhaust piston assembly •... - Page 18 Service Instructions Service Steps Procedure with the Air Processing Unit (APU) removed from the vehicle (for removal see section 3 4) Removing the old purge valve Step Service task - Read and understand all steps before commencing work! Clean the outside of the APU and its surroundings to prevent entry of dirt. Position APU so that the purge valve points vertically upwards.
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Page 19: Disassembling And Assembling The Tyre Inflator (F)
Service Instructions 3 7 Disassembling and Assembling the Tyre Inflator (F) Part Identification Item Description Compression spring Valve tappet Sealing ring O-ring (7 x 1,5) Threaded connector Protective cap Note that component numbering may not correspond to that shown on separate Service Kit leaflets. For Service Kit Part Number see www.knorr-bremseCVS.com Service Steps... -
Page 20: Replacement Of The Double Pressure Sensor (H)
Service Instructions 3 8 Replacement of the Double Pressure Sensor (H) Part Identification Item Description O-ring Screw Double pressure sensor assembly Note that component numbering may not correspond to that shown on separate Service Kit leaflets. For Service Kit Part Number see www.knorr-bremseCVS.com Service Steps Step Service task... -
Page 21: Removal And Replacement Of The Time Switch Piston (I)
Service Instructions 3 9 Removal and Replacement of the Time Switch Piston (I) Service kit parts list Description Air Processing Unit (APU) housing Piston (with K-ring) Compression spring O-ring Ø 77 x 3 mm 1 Cover Screws Torque 6+2 Nm 4 Assembly grease 5 g 1 •... - Page 22 Service Instructions Fitting the new time switch piston and seals Step Service task - Read and understand all steps before commencing work! Check that the sliding surfaces in housing (1) and in cover (5) are clean. Lubricate new O-ring (4), inside wall and sealing surface of cover (5), and central bore of APU housing (1) with grease (7) (see Fig.4).
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Page 23: Refitting The Air Processing Unit To The Vehicle
Service Instructions 3 10 Refitting the Air Processing Unit to the Vehicle Fig. 1 Fig. 2 Recommended Tightening Torques for Air Ports Max torque Conventional face sealing metric ports [Nm] M12 x 1.25 M12 x 1.5 M12 x 1.75 M16 x 1.5 M22 x 1.5 Service Steps Step Service task... - Page 24 Fax: +41 44 888 77-50 Shanghai Fax: +32 1524 9240 Tel: +86 21 3858-5800 Turkey Poland Fax: +86 21 3858-5900 Knorr-Bremse Polska SfN Sp. z o.o. Knorr-Bremse Czech Republic Knorr-Bremse Systémy pro Warsaw Ticari Araç Fren Sistemleri Tic. Ltd. Sti. China uzitková...
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